Charles R. Goulding and Kate Esposito explore how 3D printing is breathing new life into Sweden’s nuclear power sector, making it faster, safer, and more resilient than ever.
Introduction: Additive Manufacturing and the Resurgence of Nuclear Energy
In the Cold War era, the nuclear industry became one of the fastest-growing markets and nuclear power was a commonly used energy source. But as time passed and tensions cooled, nuclear power faded into obscurity, and many plants were shut down and decommissioned. However, the current need for substantially more electric energy, particularly for artificial intelligence (AI) data centers, has helped nuclear power rise again in the modern age. 3D printing is playing an increasingly important role in both the repair and maintenance of existing nuclear plants and the design of new plants.
Sweden, one of the first countries to utilize 3D-printed components within nuclear reactors, has especially witnessed a resurgence in its nuclear energy sector. Key companies such as Vattenfall, Westinghouse, and Fortum are at the forefront of merging nuclear power and additive manufacturing in Sweden’s power plants. By embracing this revolutionary technology, Sweden is on its way to becoming a global leader in nuclear power.
How Additive Manufacturing is Transforming the Nuclear Power Industry
Many nuclear reactors are over 50 years old, meaning they frequently need part replacements. However, this poses a challenge because these components are often difficult to find or no longer in production. Without replacement parts, these reactors are forced to enact expensive planned shutdowns or close indefinitely. To solve this problem, many leading nuclear companies are turning towards additive manufacturing. With this technology, complex components and specialized parts can be created in minutes using almost any type of alloy. This enables corporations to control and prioritize production themselves rather than relying on outside suppliers and ensures that reactors will not have to close because of irreplaceable parts.
Additive manufacturing also enables rapid prototyping and increases efficiency. 3D-printed components can be used to construct designs quickly and modify them as needed, allowing flaws to be identified and fixed much faster than with traditional manufacturing. This reduces development time and makes production more cost-effective and less wasteful. Furthermore, additive manufacturing’s layer-by-layer printing method ensures there is very little excess material and decreases construction errors.
To improve spent nuclear fuel storage, companies have begun using 3D printing to create sealed steel concrete containers. Researchers at the Oak Ridge National Laboratory (ORNL) printed an 837-pound stainless steel canister to hold fuel, which passed both drop and puncture resistance tests. This proves additive manufacturing can streamline the production of nuclear waste containers, which is highly beneficial because faster deployment of these canisters helps support reactor operations and safely store spent fuel.
Applications of 3D Printing Across Sweden’s Nuclear Power Plants
Sweden currently has three nuclear power plants and six nuclear reactors in operation at Forsmark, Oskarshamn, and Ringhals. The plants have had their lifetimes extended from 60 to 80 years, meaning that many components within the reactors will need to be replaced. As a result, additively manufactured parts have been pre-emptively installed in all three plants. While current applications are limited to parts not exposed to high pressure, international standards are being developed for pressure-exposed components to ensure 3D printing can be utilized wherever necessary.
Vattenfall, which owns five of Sweden’s six nuclear reactors, has long recognized the potential of additive manufacturing within the nuclear sector. In 2017, the Vattenfall-owned Ringhals plant financed a 3D printer together with four other companies in the region. Since then, they have used the machine to manufacture pipes, valves, pump housings, and other parts. In 2022, the first 3D-printed stainless steel fuel component was installed at Vattenfall’s Forsmark plant. Creating this part traditionally requires multiple steps and a high level of supervision. Using additive manufacturing, this component was completed in one stage and in a record amount of time. Vattenfall believes their next step will be to set up an in-house 3D printing facility to supply the company’s other nuclear power plants with spare parts.
Westinghouse Electric Sweden AB, a subsidiary of Westinghouse Nuclear, is a developer of 3D-printed parts for use in the nuclear sector. In 2022, Westinghouse installed 3D-printed nuclear fuel debris filters in the Nordic Boiling Water Reactor (BWR) unit at Sweden’s Oskarshamn plant. The filters have enhanced capture features to block debris from entering the fuel assembly and potentially damaging the cladding, which could cause expensive outages. Reducing the risk of fuel damage is extremely important, and the success of the filter has increased confidence in both nuclear power and additive manufacturing technologies. Since then, Westinghouse has continued to develop their 3D printing capabilities. The company is experimenting with different types of additive manufacturing, including powder bed fusion, hot wire laser welding, and cold spray coatings to develop the best 3D-printed parts possible.
Fortum, a Finnish energy company, is a co-owner of both the Oskarshamn and Forsmark plants in Sweden. In 2021, they began testing the first valve featuring a 3D-printed housing chamber at the Olkiluoto nuclear power plant, located on the west coast of Finland. The tests were successful, with the housing chamber performing exactly as planned. As a result of this achievement, Fortum has decided to further develop 3D printing technologies for use within its nuclear plants. It is possible that the company will look to implement its designs at Oskarshamn and Forsmark.
The Research and Development Tax Credit
The now permanent Research and Development (R&D) Tax Credit is available for companies developing new or improved products, processes, and/or software. 3D printing can help boost a company’s R&D Tax Credits. Wages for technical employees creating, evaluating, and revising 3D printed prototypes are typically eligible expenses toward the R&D Tax Credit. Similarly, when used as a method of improving a process, time spent integrating 3D printing hardware and software can also be an eligible R&D expense. Lastly, when used for modeling and preproduction, the costs of filaments consumed during the development process may also be recovered.
Whether it is used for creating and testing prototypes or for final production, 3D printing is a great indicator that R&D Credit-eligible activities are taking place. Companies implementing this technology at any point should consider taking advantage of R&D Tax Credits.
Conclusion: Additive Manufacturing and the Future of Nuclear Power
Additive manufacturing is a revolutionary technology that is becoming increasingly popular across many industries, especially the nuclear energy sector. Sweden’s implementation of 3D printing across its nuclear power plants highlights the country’s understanding that this technology is the future of product development and production. By taking advantage of all that additive manufacturing has to offer, Sweden is positioning itself to become a global leader in nuclear power in the near future.
